Commercial and Residential Self-Regulating Heating Products

Commercial and Residential Self-Regulating Heating Products Application and Design Guide H53585 (800) 545-6258 www.tycothermal.com

Table of Contents Introduction 1 Heating Cables Selection Guide 1 Product Line 1 Accessories 3 Technical Information 4 Pipe Freeze Protection 6 WinterGard 120-V heating cable 6 Metal or plastic piping up to 2 inches in diameter in dry locations WinterGard Plus heating cable 7 in dry locations Large piping up to 6 inches in diameter WinterGard Wet heating cable in 8 wet locations Gardian preassembled heating cable 9 Pipe runs up to 100 feet, up to 2 1/2 inches in diameter Designing a Cut-to-Length Pipe Freeze Protection System 10 How to design your WinterGard pipe freeze protection system 10 Preassembled Heating Cable Design 16 on Pipes How to design your Gardian pipe 16 freeze protection system Roof and Gutter De-Icing 18 De-ice roofs and gutters with 18 WinterGard Wet and Gardian heating cables Designing a Roof and Gutter 20 De-Icing System with WinterGard Wet Heating Cables How to design your roof and gutter 20 de-icing system Designing a Roof and Gutter De-Icing 23 System with 120-V Gardian Preassembled Heating Cables How to design your roof and gutter de-icing 23 system for smaller jobs

Refrigeration Applications 25 WinterGard Plus heating cable 26 Plastic and other pipes in dry locations WinterGard Wet heating cable 27 Wet locations FreezeGard self-regulating crankcase 28 heaters for refrigeration compressors Prolong motor life and increase compressor efficiency General Information 30 Product Data Table 30

Introduction Raychem commercial and residential self-regulating heating products are the ideal solution for pipe freeze protection, roof and gutter de-icing and crankcase heating applications. These products include WinterGard, WinterGard Plus and WinterGard Wet cut-tolength heating cable systems, Gardian preassembled heating cables and FreezGard crankcase heaters. This application and design guide applies to these Raychem heating products only and is intended to assist in the selection of the appropriate heating cable, connection kits and accessories. Following the recommendations in this guide and those of your Tyco Thermal Controls representative will result in the selection of a reliable and energy-efficient system. Heating Cables Selection Guide Application Freeze Protection WinterGard WinterGard Plus WinterGard Wet Gardian 120 V Gardian 240 V Pipes in dry areas Pipes in wet areas Roof and Gutter De-icing Crankcase Heating FreezGard Product Line 120 Volt, 3 watt Cut-to-length for small pipes 120 Volt, 6 watt 240 Volt, 6 watt Cut-to-length for large pipes There s a heating cable just right for the job: WinterGard heating cable, 3 watts/ft Catalog # Description Voltage Reel Length (ft) H311100 TruckPak* 120 100 H311250 Reel 120 250 WinterGard Plus heating cable, 6 watts/ft Catalog # Description Voltage Reel Length (ft) H611050 Box 120 50 H611100 TruckPak* 120 100 H611250 Reel 120 250 H621050 Box 240 50 H621100 TruckPak* 240 100 H621250 Reel 240 250 *TruckPak consists of a 100-foot cable reel, two power connections, one splice/tee kit, one roll of application tape, and 10 Electric Traced labels. 1

120 Volt, 6 watt 240 Volt, 6 watt Large pipes Cut-to-length for wet locations, roof de-icing, and drain lines 120 Volt, 6 watt 240 Volt, 6 watt Preassembled for pipes Preassembled for roofs 120 Volt 240 Volt Compressor crankcase heating WinterGard Wet heating cable, 6 watts/ft Catalog # Description Voltage Reel Length (ft) H612050 Box 120 50 H612100 TruckPak* 120 100 H612250 Reel 120 250 H612500 Reel 120 500 H6121000 Reel 120 1000 H622050 Box 240 50 H622100 TruckPak* 240 100 H622250 Reel 240 250 H622500 Reel 240 500 H6221000 Reel 240 1000 Gardian heating cable, 6 watts/ft Catalog # Voltage Preassembled Length (ft) W51-6P 120 6 W51-12P 120 12 W51-18P 120 18 W51-24P 120 24 W51-50P 120 50 W51-75P 120 75 W51-100P 120 100 W52-6L 240 6 W52-12L 240 12 W52-18L 240 18 W52-24L 240 24 FreezGard crankcase heater Catalog # Voltage Preassembled Length (ft) CCH-1C 120 4 CCH-2C 240 4 *TruckPak consists of a 100-foot cable reel, two power connections, one splice/tee kit, one roll of application tape, and 10 Electric Traced labels. Note: Use only in ordinary (nonhazardous) areas. Do not expose to any chemicals. In wet areas, use only WinterGard Wet or Gardian. Warning: Fire Hazard. To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with the requirements of Tyco Thermal Controls, agency certifications, and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit protection. 2 Note: This application guide does not take the place of the installation instructions. Carefully follow the installation instructions included in the Raychem accessory kits. Pipes are shown without insulation for illustrative purposes only.

Accessories Catalog number Description Use H900 Power Connection A hardwired power connection and end seal for one heating cable Kit (hardwired) circuit. (Does not include junction box.) H903 H908 H910 H912 Fiberglass Application Tape To attach heating cable to the pipe. Includes 1 roll (66 ft) of tape and 10 warning labels. 120-V Plugin Power connection with built-in ground-fault A plug-in 120-V, 15-A power Connection Kit equipment protection (GFEP) and end seal for one heating cable circuit. Splice and Tee Kit Gel-filled End Seal Provides material for one splice or one tee and one end seal. Two end seals for sealing the ends of heating cables. H913 Roof Clips Clips to attach WinterGard Wet or Gardian heating cable to the roof surface. Kit contains 10 clips for approximately 7 linear feet of roof edge. H914 H915 H921 Roof Clips (Bulk Pack) Downspout Hanger 120-V Groundfault Protected Junction Box Clips to attach WinterGard Wet or Gardian heating cable to the roof surface. Bulk pack kit contains 50 clips for approximately 35 linear feet of roof edge. Protects one WinterGard Wet or Gardian heating cable from damage caused by sharp edges in gutter and downspout applications. Also provides strain relief. Kit contains one downspout hanger bracket. Outdoor-rated junction box with built-in ground-fault protection for hardwire connection of all 120-V, 20-A Raychem cut-to-length heating cables. H900 Power Connection Kit must be used with the H921 Junction Box. Important: Use only these Raychem accessories with Raychem heating cables. Thermostats and Controllers AMC-F5 Fixed Set Point Thermostat RM-3 RM-4 Snow Controller Snow Controller with Built-in GFEP Thermostat with fixed nonadjustable set point of 40 F. Can be used in an ambient-sensing or line-sensing mode. 120-V automatic snow controller detects precipitation and low temperature. 208 240 V automatic snow controller detects precipitation and low temperature. Includes groundfault equipment protection (GFEP). 3

Technical Information Technology Raychem quality design means superior heating systems Self-regulation Parallel circuitry The self-regulating design of Raychem heating cables eliminates worry about overheating or burnouts from overlapping. The conductive polymer core automatically adjusts heat output at each point along the pipe. Unlike conventional heating cables, Raychem heating cables feature parallel circuitry. This means you can cut it to your desired length while maintaining the power output. Proven advantages for you Fast, easy to install. Thanks to their self-regulating, parallel-circuit design, Raychem heating cables require no complex installation procedures. They can be straight-traced, spiraled, or overlapped. On the job, you can cut them to the exact length needed and splice or tee them, adapting each heating-cable circuit as the job requires. Bus wires Reliable performance. Raychem heating cables provide years of reliable performance, so you re not bothered by breakdowns or callbacks. They will protect against freezing this winter and for many winters to come. Designed flexibility. Hardwire them or plug them in. With two options of power connection kits, the choice is yours. There s even a preassembled heating cable available in convenient lengths to handle small jobs fast. Convenient and economical. For larger jobs, you can simply cut the exact amount of heating cable you need right from the reel. No more wasted heating cable or extra trips to the supply house, because you always have the right size with you. 4

Warm pipe Few conductive paths Minimum heat output Cool pipe Some conductive paths Moderate heat output Cold pipe Many conductive paths High heat output Parallel circuitry (current flows between bus wires) Selfregulating conductive core Electrical insulating jacket Tinned copper braid Waterproof polyolefin outer jacket* *WinterGard Wet and Gardian heating cables only Safe on plastic pipes. Raychem heating cables can be used on plastic as well as metal pipes. Their self-regulating heating core adjusts automatically, to protect against overheating or developing hot spots when overlapped or covered with insulation. Energy-efficient. Raychem heating cables self-regulating core generates heat when and where it s needed. The core continuously adjusts its heat output to the environment at every point along the heating cable, thus reducing the overall energy cost for the season. 5

Pipe Freeze Protection WinterGard 120-V heating cable Metal or plastic piping up to 2 inches in diameter in dry locations For design flexibility, use WinterGard cut-to-length heating cable. It s the economical solution for both metal and plastic pipes with circuit lengths up to 250 feet. See pages 10 15 for information to help you design your Raychem freeze protection system and pages 30 and 31 for product data. WinterGard cable is the economical way to winterize cold-water, service, and wastewater lines.* Use WinterGard cable to freeze-protect water-service systems. It s ideal for both residential and commercial buildings. 6 *Fully insulate for a complete installation.

WinterGard Plus heating cable in dry locations Large piping up to 6 inches in diameter Designed for more demanding residential/commercial applications, WinterGard Plus 120-V and 240-V heating cables with a durable metal braid are the right choice for larger plastic and metal pipes with diameters up to 6 inches, circuit lengths up to 200 feet for 120 V and 400 feet for 240 V. WinterGard Plus cables keep large diameter pipes freeze-free year-round.* Long piping up to 6 inches in diameter WinterGard Plus 6 watt, 240-V heating cables are especially designed to save installation time and money in applications requiring long circuit lengths (up to 400 feet). *Fully insulate for a complete installation. 7

WinterGard Wet heating cable in wet locations A waterproof outer jacket makes WinterGard Wet 6 watt, 120-V and 240-V heating cables the answer for freeze protection in wet locations such as drain lines. With the waterproof outer jacket, WinterGard Wet heating cables are ideal for providing freeze protection of metal or plastic pipes in wet environments or for de-icing drain lines. For marine applications or where moisture is a consideration, WinterGard Wet heating cable is the answer.* The metal braid and additional outer jacket make WinterGard Wet heating cable the best choice for applications such as water supply lines in outdoor locations. 8 *Fully insulate for a complete installation.

Gardian preassembled heating cable Pipe runs up to 100 feet, up to 2 1/2 inches in diameter The perfect solution for small applications and short pipe lengths, Gardian 120-V cable is available in lengths of 6, 12, 18, 24, 50, 75, and 100 feet. Gardian 240-V cable is available in 6, 12, 18, and 24-foot preassembled lengths. Use the tables on pages 16 and 17 to select the right Gardian cable for your job. With the Gardian preassembled heating cable, there s no assembly required. Just attach the cable to the pipe, insulate it, and plug it in. Use Gardian cable for intake and drain lines, water meters, outside pipes, and taps. It s ideal for pipes in unheated attics, basements, and garages.* The 240-V preassembled Gardian heating cable is easy and convenient for use in refrigeration applications. It prevents freeze-up problems on freezer doors and in drain pans and drain lines. *Fully insulate for a complete installation. 9

Designing a Cut-to- Length Pipe Freeze Protection System Step 1: Step 2: How to design your WinterGard pipe freeze protection system To design your WinterGard system, follow the step-by-step guidelines that follow, referring to the shaded tables where indicated. Collect the necessary information Information needed Example Type of pipe (metal or plastic) Pipe size (0.5 6 in) Lowest expected air temperature (0 F 40 F) Insulation thickness (0.5 2 in) Voltage (120 V or 208 240 V) Location (wet or dry) Metal pipe 2.5 in 20 F 0.5 in 120 V Wet Ensure your application complies with the product data (Table 13) on pages 30 and 31. Determine heating cable type 120 V 208 V 240 V Dry H311, H611, H612 H621, H622 Wet H612 H622 Table 1: WinterGard H311 WinterGard Plus H611, H621 WinterGard Wet H612, H622 For metal pipes* Lowest air Insulation temperature thickness 0.5 in 0 F 1.0 in 1.5 in 0.5 in 1.0 in 20 F 1.5 in 2.0 in 0.5 in 1.0 in 40 F 1.5 in 2.0 in Pipe size (in inches) 0.50 0.75 Table 2: WinterGard H311 WinterGard Plus H611, H621 WinterGard Wet H612, H622 10 For plastic pipes* Lowest air Insulation temperature thickness 0.5 in 0 F 1.0 in 1.5 in 0.5 in 1.0 in 20 F 1.5 in 2.0 in Pipe size (in inches) 0.50 0.75 0.5 in 1.1 1.1 1.0 in 40 F 1.5 in 2.0 in * Information is based on pipes with fiberglass insulation or equivalent and minimum maintain temperature of 40 F.

Step 3: Determine the heating cable wattage and spiraling ratio Use Table 1 to select heating cables for insulated metal pipes. Use Table 2 to select heating cables for insulated plastic pipes. Read across the table to find your pipe diameter, then drop down to the line corresponding to the lowest air temperature for that application and the correct insulation thickness. The cell at that intersection has a particular shading and may have a number. The shading indicates which heating cable to use (key to the shading appears above table). A number represents the spiraling ratio (feet of heating cable per foot of pipe). If no number appears in the cell, straight trace the pipe. If a number does appear in the cell, spiral trace the pipe. If your spiraling ratio is 2.0, multiple-trace the pipe using two straight traces at the 4 o clock and 8 o clock positions. If your spiraling ratio is 3.0, multiple-trace using three straight traces at the 11 o clock or 1 o clock position and at the 4 o clock and 8 o clock positions. Key to Tables 1 and 2: H311 H611, H621, H612, H622 Increase insulation thickness 1.00 1.25 1.50 2.00 2.50 3.00 4.00 6.00 1.3 1.8 1.1 1.3 1.5 1.8 3.0 1.1 1.5 1.1 1.1 1.2 1.4 1.7 2.0 3.0 1.1 1.4 1.9 1.4 1.1 1.00 1.25 1.50 2.00 2.50 3.00 4.00 6.00 1.2 1.4 1.7 2.0 3.0 1.2 1.6 1.2 1.1 1.3 1.5 1.8 2.0 3.0 1.1 1.2 1.4 1.8 3.0 1.1 1.3 1.7 1.4 1.5 1.8 2.0 3.0 3.0 1.1 1.2 1.4 1.6 1.9 3.0 1.1 1.2 1.4 1.7 3.0 1.1 1.3 1.8 11

Step 4: Formula: Table 3: Calculate the total heating cable length Length = A + B + C + D + E + F A Pipe length x spiral ratio* B 4 ft x # gate/globe valves x length adjustment factor** x spiral ratio* C 2 ft x # ball/butterfly valves/flanges/supports x length adjustment factor** x spiral ratio* D 1 ft for each power connection E 2 ft for each splice connection F 3 ft for each tee connection = Total heating cable length (ft) * From Step 3 ** See Table 3 below Heating cable length adjustment Pipe Size Factor 1/2 in 0.04 1 in 0.08 2 in 0.17 3 in 0.25 4 in 0.33 5 in 0.42 6 in 0.50 Example: (taken from page 10) Pipe length 50 ft Spiral ratio 1.3 (from Table 1, pages 10 and 11) Globe valves 3 (each 0.5 ft long) Pipe supports 10 supports for 1-inch pipe Power connections 1 Splice connections 1 WinterGard heating cable required A Pipe length x spiral ratio = 50 ft x 1.3 = 65.0 ft B 3 globe valves (0.5 ft. each) = 4 ft x 3 x 0.5 x 1.3 = 7.8 ft C 10 pipe supports = 2 ft x 10 x 0.085 x 1.3 = 2.2 ft D 1 power connection = 1 ft x 1 = 1.0 ft E 1 splice connection = 2 ft x 1 = 2.0 ft F 0 tee connection = 0 = 0 Total heating cable length required = 78.0 ft 12

Step 5: Example: Table 4: Determine the number of heating cable circuits For the maximum heating cable circuit length permitted for a given circuit breaker rating, refer to Table 4 below. Find the appropriate row according to the selected heating cable type and circuit breaker rating. Move across the row to the appropriate minimum start-up temperature. (Use 40 F start-up temperature unless 0 F is required when start-up is below the freezing point.) If the total heating cable length is greater than the maximum circuit length, use shorter lengths and more circuits. Make sure that each circuit is less than the maximum circuit length shown in Table 4. Select the smallest circuit breaker appropriate for your circuit length. You have: WinterGard Wet heating cable: 120 V Start-up temperature: 40 F Circuit breaker rating: 15 amps Total heating cable length: 78.0 ft You find: 150 ft maximum circuit length You need: 1 heating cable circuit Maximum heater circuit length on pipe* Heater type WinterGard 120 V H311 WinterGard Plus 120 V H611 WinterGard Plus 240 V H621 WinterGard Wet 120 V H612 WinterGard Wet 240 V H622 Circuit breaker rating (A) Maximum heater length (ft) per circuit at start-up temperature* 0 F 40 F 15 150 250 20 200 250 30 250 250 15 125 150 20 140 195 30 200 200 15 200 255 20 250 340 30 375 400 15 125 150 20 140 195 30 200 200 15 200 255 20 250 340 30 375 400 * Maximum circuit lengths are based on start-up load. Steady state amperes per foot is dependent upon heating cable temperature. 13

Step 6: Select the accessories The diagram below shows typical heating systems assembled with the proper Raychem accessories. Either the H900 or H908 power connection kit must be used. See Table 5 to select additional accessories that may be needed for your installation. 14

Table 5: Accessories for Raychem heating cable for pipe applications Catalog number Description Use H900 H903 H908 H910 H912 H921 Thermostat AMC-F5 Power Connection Kit (hardwired) Fiberglass Application Tape 120-V Plugin Power Connection Kit Splice and Tee Kit Gel-filled End Seal 120-V Groundfault Protected Junction Box Fixed Set Point Thermostat A hardwired power connection and end seal for one heating cable circuit. (Does not include junction box.) To attach heating cable to the pipe. Includes 1 roll (66 ft) of tape and 10 warning labels. A plug-in 120-V, 15-A power connection with built-in groundfault equipment protection (GFEP) and end seal for one heating cable circuit. Provides material for one splice or one tee and one end seal. Two end seals for sealing the ends of heating cables. Outdoor-rated junction box with built-in ground-fault protection for hardwire connection of all 120-V, 20-A Raychem cut-to-length heating cables. H900 Power Connection Kit must be used with the H921 Junction Box. Thermostat with fixed nonadjustable set point of 40 F. Can be used in an ambient-sensing or line-sensing mode. Step 7: Install the system. Refer to installation instructions in the H900 or H908 kit. Warning: Fire Hazard. To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with the requirements of Tyco Thermal Controls, agency certifications, and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit protection. 15

Preassembled Heating Cable Design on Pipes How to design your Gardian pipe freeze protection system Use Tables 6 and 7 below to select the correct heating cable. Add 1 foot to the pipe length for each valve or spigot in the pipe system. Table assumes lowest outside temperature is 0 F, with a minimum of 1/2 inch fiberglass insulation or equivalent. For protection to 20 F, use 1 inch fiberglass insulation or equivalent. Table 6: Table 7: 16 120 V for Metal Pipes Pipe diameter (in) Pipe diameter (in) Pipe diameter (in) Pipe diameter (in) 120 V for Plastic Pipes 240 V for Metal Pipes Pipe length (ft) 240 V for Plastic Pipes Pipe length (ft)

Raychem 120-V Gardian cables are available in 6, 12, 18, 24, 50, 75, and 100 foot lengths, and each comes assembled with a 30-inch power cord and plug. Raychem 240-V Gardian heating cables are available in 6, 12, 18, and 24 foot lengths. Each comes assembled with a 30-inch power cord for terminating in a junction box. Pipe length (ft) Pipe length (ft) Table 8: Accessories for Gardian 120-V and 240-V preassembled heating cables on pipes Catalog number Description Use H903 Fiberglass Application Tape To attach heating cable to the pipe. Includes 1 roll (66 ft) of tape and 10 warning labels. Warning: Fire Hazard. To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with the requirements of Tyco Thermal Controls, agency certifications and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit protection. 17

Roof and Gutter De-Icing De-ice roofs and gutters with WinterGard Wet and Gardian heating cables Winter storms cause ice and snow build-ups on roofs and in gutters. Downspouts clog, intensifying the problem. Serious structural damage may result when melting snow penetrates under the roof surface and refreezes. Gutters and downspouts crack, sag, and break from the ice pressure. Put an end to ice buildups and to costly repairs. Reliably de-ice roofs of all kinds, including metal, shingle, and tile. Keep roof drains in residential applications running free. Note: For commercial building with large flat roofs contact Tyco Thermal Controls, (800) 545-6258. The roof and gutter de-icing systems covered in this design guide are for normal winter conditions. For extreme winter conditions with snow fall accumulation of 9 inches or more and ambient temperatures below 0ºF contact Tyco Thermal Controls, (800) 545-6258. 18

Easy to install for any size job Reliable Energy-saving For larger jobs, WinterGard Wet heating cable can be cut to the exact length you need. With its preassembled design, Gardian heating cables are ideal for small jobs such as porches and overhangs. With WinterGard Wet and Gardian heating cables self-regulating design there are no burnouts caused by overlapping. And the durable metallic braid and waterproof outer jacket provide additional protection against damage. WinterGard Wet and Gardian heating cables automatically save on energy costs by increasing heat output when snow and ice are present and decreasing output when ice melts away. The heating cables supply heat when and where it s needed. Drain removes melt water below the frost line. Accumulated ice can be removed. Internally trace downspout and downspout drain lines. Note: WinterGard Wet cannot be installed inside any storm drains, or in downspout drains where oil or grease may be present. 19

Designing a Roof and Gutter De-Icing System with WinterGard Wet Heating Cables Step 1: Formula: Example: Table 9: How to design your roof and gutter de-icing system To set up your de-icing system to prevent ice buildup on roof edges or in gutters and downspouts, follow these four steps: Calculate heating cable length. Find the number of feet of heating cable needed per foot of roof edge in Table 9 below. Then, calculate the amount of total heating cable length you need using the following formula: Length = A + B + C + D + E + F + G A Roof edge length (ft) x feet of heating cable per foot of roof edge (from Table 9) B Roof edge length (ft) x 0.5* C Total gutter length (ft) D Total downspout length (ft) + 1 (ft) E 3 ft for each power connection F 2 ft for each splice connection G 3 ft for each tee connection = Total heating cable length (ft) * Roof extension: This length allows the heating cable to extend into the gutter to provide a continuous drain path, or where no gutters are present, extends beyond the roof edge to form a drip loop. WinterGard Wet heating cable required: Overhang: 12 in A Roof edge: 50 ft x 2.3 ft (from Table 9) = 115 ft B Roof extension: 50 ft x 0.5 = 25 ft C Roof gutter: 50 ft = 50 ft D Downspout: 15 ft + 1 ft = 16 ft E Power connection: 3 ft x 2 ea = 6 ft Total WinterGard Wet cable required: = 212 ft WinterGard Wet cable length for roof de-icing Length of heating cable per foot of roof edge (feet) Standing seam metal roof: Eave overhang Shingle roof 18 in seam 24 in seam 0 2.0 ft 2.5 ft 2.0 ft 12 in 2.8 ft 2.8 ft 2.4 ft 24 in 3.8 ft 3.6 ft 2.9 ft 36 in 4.8 ft 4.3 ft 3.6 ft Note: Tyco Thermal Controls recommends a gutter and downspouts to provide a continuous path for melted water. If downspout is in the middle of the run, loop the heating cable down and back up. Double the length of the downspout for determining the length of heating cable to install. For valleys, run the heating cable two thirds of the way up and down the valley. For gutters 5 6 inches wide use 2 runs of heating cable. For gutters wider than 6 inches contact Tyco Thermal Controls, (800) 545-6258. 20 = 2 feet

Step 2: Example: Table 10: Determine maximum heating cable circuit length. Refer to Table 10 below for the maximum heating cable circuit length permitted for a given circuit breaker rating. Choose circuit breaker rating and read across to the right column. Select the smallest circuit breaker appropriate for your circuit length. If your total heating cable length is greater than the maximum circuit length shown in Table 10, split the heating cable into more circuits. You have: 212 ft total heating cable length 120 V @ 32 F start-up Circuit breaker rating: 20 amps You find: 165 ft maximum circuit length Using WinterGard Wet 120-V heating cable, you need two heating circuits: Circuit 1: 143 ft heating cable for roof edge and power connection Circuit 2: 20 amp breaker 69 ft heating cable for gutter, downspout, and power connection 15 amp breaker Alternatively, using WinterGard Wet 240-V cable with a 240-V power supply @ 32 F start-up; this installation would require only one 212 ft heating circuit with a 15 amp breaker. Maximum heating cable circuit length for roof and gutter de-icing, downspouts and refrigeration condensate drains* Maximum heater length Circuit (ft) per circuit for min. breaker start-up temperature Heating cable type rating (A) 0 F 32 F WinterGard Wet 120 V 15 100 125 H612 20 125 165 30 150 200 WinterGard Wet 240 V 15 200 250 H622 20 250 320 30 305 400 *Maximum circuit lengths are based on start-up load. Steady state amperes per foot is dependent upon heating cable temperature. The National Electrical Code requires ground-fault protection of equipment for snow-melting and de-icing applications. The H908 and H921 kits are equipped with built-in ground-fault protection of equipment. Note: For additional information, refer to the WinterGard Wet Design Installation and Maintenance Guide (H56804). 21

Step 3: Select WinterGard Wet accessories: Catalog number Description H900 Power Connection Kit (hardwired) H908 120-V Plug-in Power Connection Kit Use A hardwired power connection and end seal for one heating cable circuit. (Does not include junction box.) A plug-in 120-V, 15-A power connection with built-in ground-fault equipment protection (GFEP) and end seal for one heating cable circuit. H910 Splice and Tee Kit Provides material for one splice or one tee and one end seal. H912 Gel-filled End Seal Two end seals for sealing the ends of heating cables. H913 Roof Clips Clips to attach WinterGard Wet or Gardian heating cable to the roof surface. Kit contains 10 clips for approximately 7 linear feet of roof edge. H914 H915 H921 Roof Clips (Bulk Pack) Downspout Hanger 120-V Groundfault Protected Junction Box Clips to attach WinterGard Wet or Gardian heating cable to the roof surface. Bulk pack kit contains 50 clips for approximately 35 linear feet of roof edge. Protects one WinterGard Wet or Gardian heating cable from damage caused by sharp edges in gutter and downspout applications. Also provides strain relief. Kit contains one downspout hanger bracket. Outdoor-rated junction box with built-in ground-fault protection for hardwire connection of all 120 V, 20 A Raychem cut-to-length heating cables. H900 Power Connection Kit must be used with the H921 Junction Box. Controllers RM-3 Snow Controller Automatic snow controller detects precipitation and low termperatures. RM-4 Snow Controller with Built-in GFEP Automatic snow controller detects precipitation and low termperatures. Includes ground-fault equipment protection (GFEP). Step 4: Install the system Follow the installation steps in the H900 or H908 Power Connection Kit. Do not install the H908 connection kits in the gutter or where it can be immersed. Warning: Fire Hazard. To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with the requirements of Tyco Thermal Controls, agency certifications, and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit protection. 22

Designing a Roof and Gutter De Icing System with 120 V Gardian Preassembled Heating Cables Step 1: Formula: Example: How to design your roof and gutter de-icing system for smaller jobs To set up your de-icing system to prevent ice buildup on roof edges on smaller jobs like porches and overhangs or in gutters and downspouts, follow these three steps: Calculate heating cable length. Find the number of feet of heating cable needed per foot of roof edge in Table 11 below. Then, calculate the amount of total heating cable length you need using the following formula: Length = A + B + C + D A Roof edge length (ft) x Feet of heating cable per foot of roof edge B Roof edge (ft) x 0.5* C Total gutter length (ft) D Total downspout length (ft) +1 (ft) = Total heating cable length (ft) * Roof extension: This length allows the heating cable to extend into the gutter to provide a continuous drain path, or where no gutters are present, extends beyond the roof edge to form a drip loop. Gardian heating cable required (shingled roof): Overhang: 12 in Roof edge: 15 ft Roof gutter: 15 ft Downspout: 15 ft (at end of circuit) Gardian heating cable required: A Roof edge: 15 ft x 2.3 (from Table 11) = 34.5 ft B Roof extension: 15 ft x 0.5 = 7.5 ft C Roof gutter: 15 ft = 15.0 ft D Downspout: 15 ft + 1 ft = 16.0 ft Total heating required: = 73.0 ft Gardian required: W51-75P Note: For lengths above 100 feet or 240 V applications, use WinterGard Wet heating cables. Table 11: Gardian cable length for roof de-icing Length of heating cable per foot of roof edge (feet) Standing seam metal roof: Eave overhang Shingle roof 18 in seam 24 in seam 0 2.0 ft 2.5 ft 2.0 ft 12 in 2.8 ft 2.8 ft 2.4 ft 24 in 3.8 ft 3.6 ft 2.9 ft 36 in 4.8 ft 4.3 ft 3.6 ft Note: Tyco Thermal Controls recommends a gutter and downspouts to provide a continuous path for melted water. If downspout is in the middle of the run, loop the Gardian down and back up. Double the length of the downspout for determining the length of Gardian to install. For valleys, run the heating cable two thirds of the way up and down the valley. For gutters 5-6 inches wide use 2 runs of heating cable. For gutters wider than 6 inches contact Tyco Thermal Controls, (800) 545-6258. 23

Step 2: Step 3: Select Gardian accessories: Catalog number Description Use H913 Roof Clips Clips to attach Gardian heating cable to the roof surface. Kit contains 10 clips for approximately 7 linear feet of roof edge. H914 H915 Roof Clips (Bulk Pack) Downspout Hanger Bracket Clips to attach Gardian heating cable to the roof surface. Bulk pack kit contains 50 clips for approximately 35 linear feet of roof edge. Protects one Gardian heating cable from damage caused by sharp edges in gutter and downspout applications. Also provides strain relief. Kit contains one downspout hanger bracket. Follow the installation steps in the Gardian installation instructions. Warning: Fire Hazard. To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with the requirements of Tyco Thermal Controls, agency certifications, and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit protection. = 2 feet 24

Refrigeration Applications Convenient Durable Efficient Ice buildup can impair performance as well as damage critical refrigeration systems. Freezeups, backups, and compressor burnouts are a real threat. Raychem heating cables and FreezGard crankcase heaters provide an easy, reliable way to control downtime and expensive repairs. Parallel-circuit design lets you cut Raychem heating cables to the precise length you need. It s easy to wrap pipes or trace problem areas without wasting product or installation time. And because self-regulating design permits overlapping, Raychem heating cables and FreezGard crankcase heaters are easy to use in confined spaces. A metal braid on all Raychem cables provides electrical ground path and adds mechanical strength. The waterproof outer jacket on WinterGard Wet heating cables makes them ideal for drains and other areas subject to wet conditions. As equipment goes through its on/off cycle, Raychem heating cables and FreezGard crankcase heaters can automatically increase heat output when temperatures drop, then decrease output as temperatures rise maintaining the equipment temperatures while minimizing energy costs. 25

WinterGard Plus heating cable Plastic and other pipes in dry locations For a variety of pipe and surface-tracing installations, WinterGard Plus heating cable gives you 6-watt/ft output in 120-V or 240-V systems to match your available supply voltage. Its adaptability to a wide range of pipe diameters and line runs makes WinterGard Plus heating cable ideal for protecting condensate drainlines from freezing in refrigeration applications.* Tracing door frames helps prevent surfaces from freezing shut. Heating cable is placed in routed section of door or door frame and must be protected from mechanical damage. *Fully insulate for a complete installation. 26

WinterGard Wet heating cable Wet locations For applications where water is present, an additional outer jacket makes WinterGard Wet heating cable both waterproof and abrasionresistant. Choose 120-V or 240-V versions, depending on your supply voltage. Waterproof jacket lets WinterGard Wet heating cable trace drain pans so water keeps flowing. Other wet locations, such as drain lines in freezer cases, avoid backup problems when internally traced with WinterGard Wet heating cable. Note: See pages 10 and 11 for information to help you design your Raychem freeze protection system. See Table 5 on page 15 to select accessories. 27

FreezGard self-regulating crankcase heaters for refrigeration compressors Prolong motor life and increase compressor efficiency When compressors operate in cold areas, refrigerant can migrate into the crankcase oil whenever the compressor is not running. On start-up, this can cause excessive motor wear and a loss of refrigeration efficiency. FreezGard self-regulating crankcase heaters provide reliable peak heating during these critical cold periods and, unlike conventional constant-wattage heaters, reduce their heating once the compressor starts up or when air temperatures rise, saving energy. Also, selfregulating heaters can be safely overlapped and closely spaced without burning out, so one size fits all hermetic and scroll compressors up to 5 HP that are 40 inch or less in circumference. Models for 120 V and 208 277 V are available, and each comes with a flexible lockstrap and prestripped 28 incj cold leads for easy connection and hardwiring. Use only with refrigeration compressors in nonhazardous areas. The FreezGard crankcase heater s self-regulating design automatically varies output to maintain adequate oil temperature, while minimizing energy use. 28

Table 12: FreezGard technical information Service voltage CCH-1C: 120; CCH-2C: 208 277 Power output at 50 F 32 watts minimum Power output at 0 F 60 watts minimum Cold lead wire gauge (AWG) 18 Cable width (inches) 0.615 Cable thickness (inches) 0.245 Cable length (inches) 48 Cold lead length (inches) 28 Maximum exposure 185 F temperature (intermittent) Insulation jacket type Modified polyolefin Compressor girth 40 inches or less circumference (wraparound) dimension 29

General Information Table 13: Product Data WinterGard H311100 H311250 Nominal service voltage 120 Minimum power output at 40 F on pipes (W/ft) 3 Nominal power output in drains, ice and snow n/a Maximum circuit length (ft) for pipes 250 Maximum circuit length (ft) n/a for roof and gutter de-icing Maximum circuit breaker size (A) 30 Weight per 100 ft (lb) 6 Maximum exposure temp. ( F) 150 Environment* Dry area pipes Approvals** UL System Listed (2) CSA Certified (4) * Use only in ordinary (nonhazardous) areas. Do not expose to any chemicals. In wet areas, use only WinterGard Wet or Gardian. ** (1) 60J9 Residential and Mobile Home Pipe Heating Cable. (2) 718K Pipe Heating Cable. (3) 877Z Roof De-Icing and Snow Melting Equipment. (4) CSA file LR21133. Power Output vs Pipe Temperature on Metal Pipes Power output (W/ft) 10 8 6 4 2 WinterGard Plus, WinterGard Wet and Gardian WinterGard 0 0 20 40 60 80 Pipe temperature ( F) 30

WinterGard Plus WinterGard Wet Gardian W51-6P W51-12P H611050 H611100 H611250 H621050 H621100 H621250 H612050 H612100 H612250 H612500 H6121000 H622050 H622100 H622250 H622500 H6221000 W51-18P W51-24P W51-50P W51-75P W51-100P W52-6L W52-12L W52-18L W52-24L 120 208 240 120 208 240 120 208 240 6 6 6 6 6 6 n/a n/a 8 8 8 n/a 200 400 200 400 n/a n/a n/a n/a 200 400 n/a n/a 30 30 30 30 30 30 6 6 9 9 n/a n/a 150 150 150 150 150 150 Dry area pipes Dry and wet area pipes, drains and roof & gutter de-icing Pipes only (2) (2) (2, 3) (2, 3) (1, 2, 3) (2) (4) (4) (4) (4) (4) (4) 31

Worldwide Headquarters Tyco Thermal Controls 7433 Harwin Drive Houston, TX 77036 USA Tel: 800-545-6258 Tel: 650-216-1526 Fax: 800-527-5703 Fax: 650-474-7711 info@tycothermal.com www.tycothermal.com Canada Tyco Thermal Controls 250 West St. Trenton, Ontario Canada K8V 5S2 Tel: 800-545-6258 Fax: 800-527-5703 Tyco, FreezGard, Gardian, TruckPak, WinterGard, WinterGard Plus, and WinterGard Wet are trademarks of Tyco Thermal Controls LLC or its affiliates. 2010 Tyco Thermal Controls LLC H53585 11/10 Important: All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their particular application. Tyco Thermal Controls makes no warranties as to the accuracy or completeness of the information, and disclaims any liability regarding its use. Tyco Thermal controls only obligations are those in the Tyco Thermal Controls Standard Terms and Conditions of Sale for these products, and in no case will Tyco Thermal Controls or its distributors be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the products. Specifications are subject to change without notice. In addition, Tyco Thermal Controls reserves the right to make changes without notification to Buyer to processing or materials that do not affect compliance with any application specification.